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SERVICE MANUAL

Screw Compressor Model: SK 26


GL---Nr.: BA---SK26.L---1.9763.50210---00 03

USE

L L L L L

. . . . . . . . . . . . . . . . . . . . . . . . . . Volt Wye---Delta Start D.O.L. Start . . . . . . . . . . . . . . . . . . . . . . . . . . psig ............................. ............................. Wiring Diagram: ..............................

L L L L L L L

Cabinet heaters 115 V receptacle Outdoor modification Rainhoods Switchable Modulation Synthetic lubricant . . . . . . . . . . . . . . . . . . . Food Grade lubricant . . . . . . . . . . . . . . . . .

Serial No.: ...............................................

Table of Contents
Chapter --- Page

Technical Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 --- 1


1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.8.1 1.8.2 1.8.3 1.9 1.10 Compressor Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Noise Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Set Point of the Safety Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fluid recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . KAESER Fluids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Compatibility of KAESER Sigma Lubricants . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance for the Electrical Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dimensional Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 1 1 1 1 1 1 1 1 1 1 1 --------------------------1 1 1 1 2 2 2 3 3 3 4 5 5

Safety Regulations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 --- 7


2.1 2.2 2.3 2.4 2.5 2.6 Explanation of Symbols and References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Compressed Air System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Environmental Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 2 2 2 2 2 ------------7 8 9 9 9 10

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 --- 11
3.1 3.2 3.3 3.4 Proper use of the Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Improper use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Compressed Air Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Copyright . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 3 3 3 --------11 11 11 11

Transport . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 12
4.1 4.2 4.3 Transport Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 12 Packaging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 12 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 --- 13

Construction and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 --- 14


5.1 5.2 5.3 5.4 5.5 5.6 Principle of Compression . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Brief Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pipe and Instrument Flow Diagram (P & I Diagram) . . . . . . . . . . . . . . . . . . . . . . . DUAL Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . QUADRO Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . VARIO Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 5 5 5 5 5 ------------14 14 14 17 18 19

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 20
6.1 6.2 6.3 Installation Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 20 Connection of the Compressed Air Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 21 Electrical Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 --- 21

Table of Contents
Chapter --- Page

Putting into Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 --- 22


7.1 7.2 7.3 7.4 7.5 7.6 7.7 7.8 7.8.1 7.8.2 Points to be Observed before Putting into Operation . . . . . . . . . . . . . . . . . . . . . . Points to be Observed before Starting the Compressor Unit . . . . . . . . . . . . . . . Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Direction of Rotation Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Motor Overload Relay Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Setting the Air System Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Functional Check of the Door Interlock Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . Measures to be taken before Initial Start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pour a small quantity of oil into the air inlet port . . . . . . . . . . . . . . . . . . . . . . . . . . Running the compressor in idle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 7 7 7 7 7 7 7 7 7 --------------------22 22 24 25 25 26 26 28 28 28

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 --- 29
8.1 8.2 8.2.1 8.2.2 8.2.3 8.3 8.4 8.5 8.6 8.6.1 8.6.2 8.6.3 8.6.4 8.6.5 8.6.6 8.6.7 8.6.8 Control Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SIGMA controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Emergency Stop Pushbutton . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Function keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Light emitting diodes and plain text display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starting and Stopping the Compressor Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Acknowledgement of Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Acknowledgement of Service Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Trouble shooting: Possible cause---Remedy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Airend temperature is too high (greater than 167F---200F) . . . . . . . . . . . . . . . Motor overload relay switches the unit off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Compressor is running but produces no pressure . . . . . . . . . . . . . . . . . . . . . . . . Oil leaks out of air filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Full---load/Idle sequence occurs too frequently (short cycles) . . . . . . . . . . . . . . Safety relief valve blows off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil inside the unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Excessive oil consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 8 ----------------------------------29 29 29 30 30 31 31 32 33 33 34 34 35 35 35 35 36

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 --- 37
9.1 9.2 9.3 9.4 9.5 9.6 9.7 9.8 9.9 9.10 9.11 9.11.1 9.12 9.13 Observe the following rules during all maintenance and servicing work: . . . . . Regular Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Opening and Closing the Compressor Package . . . . . . . . . . . . . . . . . . . . . . . . . . Checking the Drive Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drive Belt Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning or Replacing the Filter Mat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning or Replacing the Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Servicing the Electric Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Testing the Safety Relief Valve on the Oil Separator Tank . . . . . . . . . . . . . . . . . . Venting the compressor unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil Filter Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal and replacement of the oil filter cartridge . . . . . . . . . . . . . . . . . . . . . . . . Oil Top ---Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning the Oil Cooler and Aftercooler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 9 9 9 9 9 9 9 9 9 9 9 9 9 ----------------------------37 38 39 40 40 41 42 42 43 43 44 44 45 47

ii

Table of Contents
Chapter --- Page

9.13.1 9.14 9.14.1 9.14.2 9.14.3 9.14.4 9.15 9.16

Removing and cleaning the oil cooler/air aftercooler . . . . . . . . . . . . . . . . . . . . . . Oil Change (Oil Separator Tank and Oil Cooler) . . . . . . . . . . . . . . . . . . . . . . . . . . Oil change using external pressure source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Oil top ---off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Draining the oil using own compressed air . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Procedure for putting back into operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Changing the Oil Separator Cartridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9 9 9 9 9 9 9 9

-----------------

47 48 50 51 51 52 52 55

10 Spare Parts and After Sales Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 56


10.1 10.2 Service parts and maintenance parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 56 Service and Maintenance Agreement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 --- 57

11 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 --- 58
11.1 11.2 Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 --- 58 Spare Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 --- 75

iii

Technical Specification
1
1.1

Technical Specification
Compressor Unit
Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SK 26 Maximum gauge working pressure . . . . . . . . 110/125/145/190 psig Minimum gauge working pressure . . . . . . . . . . . . . . . . . . . . . . 80 psig Free air delivery at max. gauge . . . . . . . . . . . . . . 92/ 87/ 80/ 65 cfm working pressure

Operating temperature approx. . . . . . . . . . . . . . . . . . . . 167---200 EF (Varies with ambient temperature and operating conditions)

Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 640 lbs Drawings: Dimensional drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . T 7471.5 P & I flow chart . . . . . . . . . . . . . . . . . . . . . . FSK26STL---00023.00 (Pipework and instrument flow chart) Electrical diagram . . . . . . . . . . . . . . . . . . . . . SSK26.Y---U1016.01

1.2

Noise Level
Noise level to CAGI---Pneurop . . . . . . . . . . . . . . . . . . . . . . . . . . 67 dB(A) at 1 m distance (free sound field measurement)

1.3

Motor
Compressor motor: Rated power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 hp Rated speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3600 rpm Specification class . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TEFC

1.4

Electrical Connection
Main voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380 V 3---phase Full load current FLA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 A Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Hz Recommended main disconnect fuses (Dual element or time---delay) . . . . . . . . . . . . . . . . . . . . . . . . . . 50 A Recommended power supply cable (Cu multi---stranded ) cross---section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 AWG Attention! Maximum dual element time -- delay fuses are selected according to 2002 N.E.C. Article 240 -- 6, 430 -- 52 and Tables 430 -- 52, 430 -- 148 & 150. Select multi-- strand copper core wire at 40C ambient temperature according to 2002 N.E.C. 110 -- 14(c), 220 -- 3, 310 -- 15, Table 310 -- 16, 430 -- 6, 430 -- 22, 430 -- 24 and Tables 430 -- 148 & 150. For electrical power supply please refer to chapter 2.3 and 6.3

1 --- 1

Technical Specification
1.5 Set Point of the Safety Relief Valve
110 psig Compressor Unit --- Activating pressure . . . . . . . . 140 psig 125 psig Compressor Unit --- Activating pressure . . . . . . . . 155 psig 145 psig Compressor Unit --- Activating pressure . . . . . . . . 175 psig 190 psig Compressor Unit --- Activating pressure . . . . . . . . 230 psig

1.6

Installation Requirements
Max. height above sea level of the place of installation . . 3000 ft. (for all heights above please contact authorized KAESER distributor) Max. ambient temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 EF Min. ambient temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 EF

Max. cooling air/inlet air temperature . . . . . . . . . . . . . . . . . . . 105 EF Exhaust air for solution A (see chapter 6.1):

Min. cooling air/inlet air temperature . . . . . . . . . . . . . . . . . . . . 40 EF

Air inlet opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4 sq.ft. Forced ventilation with exhaust ventilator . . . . . . . . . . . . . . 2350 cfm at static pressure of 0.4 inches water column Exhaust air for solution B (see chapter 6.1): Exhaust air used for space heating: Heating duct w x h . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 x 20

1.7

Oil Capacities
Total oil capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.17 gal After oil change or after long period of storage Quantity required for prelubrication of the airend . . . . . . . . . 0.5 quart (Refer to chapter 7.8.1)

1 --- 2

Technical Specification
1.8 Fluid recommendations
Lubrication of an air compressor is essential to reliable operation. Carbon and varnish can form in compressor oils. These deposits block the flow of lubricant and cause excessive wear and failure of moving parts. Contamination of the fluid can allow the formation of acids, causing extensive internal corrosion. Water may be condensed decreasing the fluid s lubricity. Fluid in rotary compressors does much more than lubricate. During the compression process, it acts as a sealant in the airend which is important for maximum efficiency. The fluid also absorbs much of the heat of compression to cool the airend and reduce the temperature of the compressed air. Its not enough that a compressor fluid lubricates well, it must stand up to the heat, pressure and contaminants that are present in every air compressor. 1.8.1 General Information KAESER synthetic lubricants should be stored in a protected location to prevent contamination. Do not re---use drums; flush and send to reconditioner. Although the KAESER synthetic is not highly flammable, it will burn. While KAESER synthetic compressor oil is less flammable than equal viscosity mineral oils, it cannot be classified as a fire---resistant fluid. It has a flash point above 460F. Since the user has total control over the conditions of the compressor lubricant, he assumes total responsibility for its safe usage. Material Safety Data Sheets are available for each lubricant from your KAESER authorized distributors. Regardless of the lubricant selected, the KAESER Sigma lubricants will separate readily from water. If condensate occurs it can easily be removed. Let the compressor sit so that any water can drain back to the separator tank and separate to the bottom. See chapter 9.14 proper draining procedure. 1.8.2 KAESER Fluids KAESER COMPRESSORS has several lubricants available that are specially formulated to match these demands. They feature excellent lubricity, outstanding demulsibility (ability to separate from water), and long life.

RECOMMENDED KAESER LUBRICANTS SIGMA LUBRICANT DESCRIPTION MAXIMUM RECOMMENDED CHANGE INTERVAL* First Oil Change M---460 S---460 * ISO 46 Semi---Synthetic Lubricant ISO 46 Synthetic Lubricant 2,000 Hours 6,000 Hours Subsequent Oil Change 4,000 Hours 8,000 Hours

Oil changes may need to be more frequent depending on ambient conditions. When high ambient temperatures or dirty conditions are present, oil changes may be necessary every 1,000 hours (4,000 hours for synthetic) or even shorter intervals. Oil change intervals required should be determined through periodic oil analysis. M---Series SIGMA compressor fluids are the highest quality petroleum lubricants. M---460 is specially blended to provide reliable performance in KAESER screw compressors.

M -- SERIES SEMI -- SYNTHETIC LUBRICANTS -

1 --- 3

Technical Specification
S-- SERIES SYNTHETIC LUBRICANTS S---Series SIGMA compressor oils are formulated from the most advanced synthetic lubricants. These synthetic lubricants begin as high quality petroleum feed stock. They are then refined, processed and purified into fluids with very consistent molecular structure. These oils are carefully blended to produce extremely consistant lubricants with superior properties. SIGMA synthetic lubricants feature all the advantages of both PAO and diester fluids. S---460 lubricant is recommended for compressors operating in ambient temperatures between 40F and 105F. S---680 lubricant may be used when ambient temperatures are always between 70F and 105F. FG---460 synthetic hydrocarbon based food grade fluid is designed for use in rotary screw compressors in the application where incidental food contact may occur with the discharge air. This fluid meets the requirements of the FDA Regulation 21 CFR 178.3570 and is USDA H---1 approved. FG---460 is approved for canning, food packing, meat and poultry processing and other applications where incidental food contact may occur. SPECIALTY KAESER LUBRICANTS (Refer to product information to determine suitability.) SIGMA LUBRICANT DESCRIPTION MAXIMUM RECOMMENDED CHANGE INTERVAL* First Oil Change S---680 FG---460 * ISO 68 Synthetic Lubricant ISO 46 Food Grade Synthetic Fluid 6,000 Hours 2,000 Hours Subsequent Oil Change 8,000 Hours 3,000 Hours

Specialty KAESER LUBRICANTS -

Oil changes may need to be more frequent depending on ambient conditions. When high ambient temperatures or dirty conditions are present, oil changes may be necessary every 1,000 hours (4,000 hours for synthetic) or even shorter intervals. Oil change intervals required should be determined through periodic oil analysis.

1.8.3

Compatibility of KAESER Sigma Lubricants All the above listed KAESER Sigma lubricants are similar to mineral oil in their compatibility with paints, seals, gaskets and hoses. The typical precautions are required when changing over from mineral oil to KAESER synthetic hydrocarbon based lubricant. Never mix lubricants of different types or brands. When switching from mineral oil to a synthetic oil, the plants system materials must be re---evaluated. Certain plastics are not compatible with synthetic oils. The following is a partial list of acceptable and not recommended materials:

1 --- 4

Technical Specification
ACCEPTABLE Viton High Nitrile Buna N Teflon Epoxy Paint Oil Resistant Alkyd Nylon Delrin Attention! Celcon Neoprene SBR Rubber Low Nitrile Buna N Acrylic Paint Lacquer Polystyrene NOT RECOMMENDED PVC ABS

Polycarbonate bowls can be etched by any synthetic lubricant. We recommend replacement with metal bowls, or the addition of metal guards.

1.9

Maintenance for the Electrical Motor


Relubricate the compressor motor bearings: Under normal operating conditions, after . . . . . . . . . . . . . 12000 h* (ambient temperature up to 77EF) Under unsuitable conditions, after . . . . . . . . . . . . . . . . . . . . 6000 h* (ambient temperature up to 105EF) but no later than . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Years * operating hours

1.10

Dimensional Drawing
(see following page)

1 --- 5

Technical Specification

1 --- 6

Safety
2 Safety Regulations
Read this service manual carefully and observe cautionary references before putting this compressor package into operation and before carrying out any maintenance.

2.1

Explanation of Symbols and References


This symbol is placed before all references to safety where danger to life and limb can occur during work. It is especially important that these rules are observed and that extreme care is taken in these cases. For their own protection, all other users must be informed of these safety rules. Observe general safety and accident prevention regulations as well as the safety rules laid down in this service manual. Attention! This symbol is placed by text where considerable attention must be paid so that recommendations, regulations, references and correct sequence of work are adhered to and that damage and/or destruction of the compressor unit and/or other equipment is prevented. This symbol identifies environmental protection measures.


-

This symbol indicates operations to be carried out by the operator or service technician. This bullet identifies listings.

Explanation of warning labels: Beware of hot surface. Do not touch surface; danger of burning.

Beware of high voltage. Do not touch electrical components; danger of electric shock. Beware! Machine starts automatically. Machine can start automatically or by remote start command. Beware of rotating parts. Do not touch rotating parts as this can cause pinching/injury.

2 --- 7

Safety
2.2 General Safety Precautions
Work on power driven systems may only be carried out by trained or specialized personnel. Work on the electrical equipment of the refrigerated dryer may only be carried out by a qualified electrician or trained personnel under the supervision of a qualified electrician according to the NEC and any applicable local codes. Prior to working on electrical systems of the compressor always perform the following steps in the sequence shown. 1. Lock the main disconnect in the off position in accordance with applicable lock out/ tag out procedures (example: OSHA CFR 29 1910.147) to ensure the compressor does not restart. 2. Ensure the package cannot be switched on again 3. Check that no voltage is present 4. Lock the isolation shut-- off valve in the closed position and vent all compressed air trapped between the compressor and the isolation shut-- off valve in accordance with applicable lock out/ tag out procedures (example: OSHA CFR 29 1910.147). Unless the Service Manual states otherwise, all pressure lines must be vented or shut off. Attention! Any alterations or reconstruction carried out without the prior written authorization of KAESER COMPRESSORS Inc. will invalidate the warranty. No welding, heat-- treatment or mechanical modifications may be carried out on pressurised components such as. pipework, air receivers, etc. Safety devices may not be modified or deactivated. Signs and labels of reference may not be removed or rendered unreadable.

Attention!

Attention!

These instructions must also be observed: Allow no open flames and flying sparks at the place of installation. Ensure that sparks or high temperatures cannot cause fire or explosion if welding is carried out on or near the compressor. Ensure that the compressor unit can breathe clean intake air that contains no damaging components. Do not allow the maximum ambient temperature to be exceeded (see chapter 1.6), otherwise special measures must be agreed between the manufacturer and the customer.

2 --- 8

Safety
Carry out oil changes according to the service manual. Use only oils recommended by the manufacturer. Do not mix cooling oils of different types. The operating temperature stipulated must be kept to and checked constantly to avoid condensate in the oil circulation. If maintenance work is carried out on any part of the oil circulation system, top up the oil in the oil separator tank to the maximum level afterwards, run the compressor for a short period and keep it under constant observation. Check the oil level again and top up with oil to replace the oil taken up by the piping and the cooling system. Use the filter cartridge of the oil separator tank only as long as the pressure drop across the filter is less than the 14.5 psi specified. Check constantly. This machine is not explosion ---proof. It may not be operated in areas in which specific requirements with regard to explosion protection are applied.

2.3

Electrical Power Supply


Attention! The main power supply and overcurrent protection must be installed by a qualified electrician in accordance with NEC, OSHA and any applicable local codes. Compressor packages must be installed with a lockable main disconnect and fuses or other short-- circuit and ground fault protection device. For fuse and wire recommendations, see chapter 1.4 Please note that the conductors, fuses and procedure are KAESERs recommendations. These recommendations do not supersede other applicable codes.

2.4

Spare Parts
Safe and reliable operation of the compressor package is guaranteed only with KAESER original spare parts and KAESER SIGMA cooling oil. Attention! Use only original parts in assemblies subject to pressure.

2.5

Compressed Air System


If a compressed air system is extended or changed, verify that the blowoff pressure and capacities of the safety relief valves on the air receiver tanks and in the system match the rating of all the compressor packages installed.

2 --- 9

Safety
2.6 Environmental Protection
Condensate drainage The condensate accumulating during compression must be fed via a suitable drainage system, collected in special canisters and disposed of according to environmental regulations. Maintenance materials/wear items/replacement parts Ensure that all wear items, maintenance and replacement parts accumulating during operation of the compressor package are disposed of according to environmental regulations. The following points must be observed: Avoid contact with skin and eyes. Do not inhale vapors and oil mist. Do not eat or drink when handling such materials. Fire, open flame and smoking are strictly forbidden.

2 --- 10

General
3 General
The service manual must always be available for use at the location of the compressor package. The right is reserved to make technical changes and improvements to equipment which may then result in discrepencies in the details of that equipment contained in this manual.

3.1

Proper use of the Compressor


The compressor package is intended solely for the purpose of generating compressed air. Any further use outside of this purpose is considered improper. The manufacturer cannot accept liability for any damage caused by such improper use; the user alone is liable for any risks incurred. Proper use of the compressor also includes adherence to the installation, removal, application, operational and maintenance instructions laid down by the manufacturer.

If the compressor package is operated in an air distribution network, the maximum network pressure may not exceed 232 psig. Attention! The equipment may only be used or serviced by authorized and trained personnel.

3.2

Improper use
Never direct compressed air toward persons. Compressed air is a concentrated form of energy and as such is dangerous to life. Attention! Inlet air may not contain any explosive or chemically unstable gas or vapour.

3.3

Compressed Air Treatment


Never use compressed air from oil injected compressor packages for breathing purposes and production methods where the air has direct contact with food, without subjecting the compressed air to additional treatment.

3.4

Copyright
KAESER COMPRESSORS, INC. All rights reserved. No part of this manual may be reproduced in any form without permission of KAESER COMPRESSORS, INC.

3 --- 11

Transport
4
4.1

Transport
Transport Instructions
We recommend a fork lift truck or lifting equipment for transporting the compressor package to avoid damage to the cabinet and framework.

min. 40

Attention!

Do not exert any side forces on the compressor package when transporting with lifting equipment!

4.2

Packaging
Always observe the instructions in chapter 4.3 when packaging the machine for storage. Use packaging suitable for the intended route if the machine is to be transported further by the customer. Overland The machine should be protected from mechanical damage by a sturdy crate and from moisture by plastic sheeting. By sea or air Special packaging instructions can be obtained from KAESER. Dispose of the packaging according to environmental regulations and recycle where possible.

4 --- 12

Transport
4.3 Storage
If the equipment is to stand idle for a long period the prescribed measures must be taken to avoid damage. If any measures can not be taken, advice should be sought from an authorized KAESER distribitor. Attention! Basically, the equipment should be stored in a dry, frost-- free room. Protect against ingress of moisture or formation of condensation. See chapter 7.8 for instructions on start-- up.

Storage up to 6 months (temporarily out of service): As an alternative to storage, the equipment can be run once a week for 30 minutes at operating temperature to ensure adequate corrosion protection. Otherwise, the measures described under Storage for longer than 6 months are to be taken. Storage for longer than 6 months: Ensure the equipment is dry and cover in plastic sheeting. Protect the interior with sufficient quantities of desiccant (silica gel or similar). Storage for longer than 12 months: Carry out the following additional maintenance tasks before putting into operation:     Change the oil filter (see chapter 9.11). Change the oil separator cartridge (see chapter 9.15). Change the oil (see chapter 9.14). Have the motor bearings checked by an authorized KAESER service technician.

Storage for longer than 3 years: After 3 years at the latest the complete technical condition of the equipment must be checked before start ---up. Attention!  Starting up the equipment without a full inspection can lead to damage.

Have the the start ---up carried out by an authorized KAESER service technician.

4 --- 13

Construction and Operation


5
5.1

Construction and Operation


Principle of Compression
The stationary compressor package is fitted with a single stage, oil---injected airend. The two rotors, the driven male rotor and the female rotor, both mounted in antifriction bearings, are fitted into the airend. As the rotors rotate, air is drawn into the upper side through the inlet port and is compressed on the lower side. The oil that is injected into the lower side absorbs heat generated by compression, prevents metal to metal contact between the rotors, seals the rotors and the housing from each other and also lubricates the antifriction bearings. The compressed air and oil mixture leaves the airend via the discharge port. 6

4 1 Drive shaft 2 Oil injection 3 Discharge port

5 4 5 6

1 Male rotor Female rotor Air inlet port

5.2

Brief Description
The compressor block is driven by an electric motor via V---belts. An oil separator cartridge is fitted into the oil separator tank allowing practically oil free compressed air supply. The control system of the compressor package ensures that compressed air is generated within the set pressure limits. Safety devices protect the compressor package against failure of important systems through automatic shut ---down. The fan ensures ventilation of the compressor package and sufficient cooling air for the air---cooled oil cooler and air aftercooler.

5.3

Pipe and Instrument Flow Diagram (P & I Diagram)


(see following pages)

5 --- 14

Construction and Operation

5 --- 15

Construction and Operation

5 --- 16

Construction and Operation


5.4 DUAL Control
p max p min

Pressure

2 3 t1

4 t2

Full load Motor power

Idle Standstill Time

In DUAL Control (combined idle and start ---stop) the compressor normally runs at full -load, idle or standstill. The controller regulates the compressor package between full -- load and idle. If the compressor package runs in idle for longer than the preset period (1) to (2), for example t1 = 6 min, the drive motor is stopped completely (2). When the lower switching point p min (3) is reached the compressor package is automatically started again. Pressure rises to the upper switching point p max (4), and the compressor package switches to idle. If the pressure falls again to, for example, p min (5) within a shorter period (4) to (5), then the compressor is automatically switched from idle to full---load. The idle period is dependent on the maximum motor starting frequency.

5 --- 17

Construction and Operation


5.5 QUADRO Control
Pressure Motor power p max pmin

Full load

Idle Standstill 1 tp rise tp decay Running period Idle/ standstill period Run ---on period Stop point for the running period or idle / standstill period pmax pmin tp rise tp decay upper switching point lower switching point pressure rise time (the time during which the air system pressure rises from the lower to the upper switching point) pressure decay time (the time during which the air system pressure decays from the upper to the lower switching point) 2 1 3 1 4 1 2 1 4 5
Time

Functional description Two fixed periods --- the running period and idle/standstill period --- are taken as the criterium for selection of the operating mode of the compressor package when the air mains pressure reaches the upper switching point. These two periods are set according to the maximum permissible cut ---in frequency of the compressor motor. The running period starts every time the compressor package is switched on. It lasts as long as the compressor motor runs and stops when the compressor package switches to full stop. The idle/standstill period starts every time the operating mode changes from full load to off load running. It runs during idle and also when the compressor package is switched to standstill after the idle period. It stops when the compressor package switches to full load. Every switching off point is delayed by the run ---on period, during which time the compressor package vents. The following switching cycles are possible: If the air systems pressure decays to the lower switching point, the compressor package switches to full load (1) irrespective of its previous operating mode. If the compressor motor was at a standstill the opening of the inlet valve is delayed to allow an unloaded compressor package start.

5 --- 18

Construction and Operation


If the air systems pressure rises to the upper switching point and the running period has already expired, the compressor package is switched off after the run ---on period has expired (2). If the air systems pressure rises to the upper switching point before the running period has expired then the pressure decay time of the previous switching cycle is taken as the criterium for the selection of the operating mode: -- If the pressure decay time tp decay was longer than the period set for the idle/standstill period, the compressor is switched to standstill after the run ---on period has expired (3). -- If the pressure decay time tp decay was shorter than the period set for the idle / standstill period, the idle mode is selected (4), that is, the inlet valve closes and the compressor is vented with running motor. When the running period expires the compressor package switches to standstill only after the run ---on period has also expired (5).

5.6

VARIO Control
Functional description: The idle period is automatically lengthened or shortened by the variable idle control in relation to the number of motor starts. The number of motor starts during the preceding hour are measured. A high switching frequency leads to longer idle periods. A low switching frequency leads to shorter idle periods.

5 --- 19

Installation
6
6.1

Installation
Installation Requirements
Attention! The compressor should be mounted on level surface. For any special application please consult with the manufacturer.

Safe operation of the compressor package is only ensured if the ambient temperature remains within the limits stated in chapter 1.6). If the compressor is used in the open, take care that it is protected against the direct rays of the sun and against the ingress of dust and rain. Install the compressor according to the following diagram. Adhere to the minimum distances shown to allow free access to the compressor package. Adequate ventilation of the compressor space is ensured only if the minimum values (see chapter 1.6) are adhered to.

30

B b

20

min. 22

35 min. 90

Exhaust ventilator min. 90 Air inlet opening 32 Measurements in inches Solution A: Forced Ventilation The ventilator intended for the compressor room must provide adequate ventilation in relation to the size of the compressor package (see chapter 1.6). 40 Exhaust duct A

B h

32

min. 90

6 --- 20

Installation
Solution B: Exhaust Air used for Space Heating The hot air is forced through a conduit (see chapter 1.6) into the room to be heated. Attention! Consult the manufacturer with regard to length of conduit and for maximum allowable pressure drop for this compressor package.

Safe operation of the compressor package is guaranteed only if the temperature limits (see chapter 1.6) of the cooling air are adhered to.

6.2

Connection of the Compressed Air Supply


Attention! The unit is set up ready to operate. Connect the discharge outlet of the compressor to the system pipework using a flexible hose line and isolation shut-- off valve with drain. Use the NPT adapter if necessary.

6.3

Electrical Connection
The main power supply and overcurrent protection must be installed by a qualified electrician in accordance with NEC, OSHA and any applicable local codes. For fuse and wire recommendations, see chapter 1.4 The compressor is wired ready for connection to the main supplies. Feed the supply cable with cores marked L1, L2, L3 and PE through the cable inlet in the base frame into the control box and connect to the terminals marked L1, L2, L3 and PE in this box. Attention! Maximum dual element time -- delay fuses are selected according to 2002 N.E.C. Article 240 -- 6, 430 -- 52 and Tables 430 -- 52, 430 -- 148 & 150. Select multi-- strand copper core wire at 40C ambient temperature according to 2002 N.E.C. 110 -- 14(c), 220 -- 3, 310 -- 15, Table 310 -- 16, 430 -- 6, 430 -- 22,430 -- 24 and Tables 430 -- 148 & 150. Wire temperature rating: 1.25 x FLA (see chapter 1.4) d 100A ! 100A wire temperature rating 60C 75C correction factor for 40C 0.82 0.88

6 --- 21

Initial Start
7
7.1

Putting into Operation


Points to be Observed before Putting into Operation
Every compressor package is given a test run at the factory and carefully inspected before shipment. The test run confirms that the package conforms to the specification data and runs perfectly. However, the compressor package could be damaged during transport. For this reason, we recommend that the package be examined for possible shipping damage. It is recommended that an operator observe the compressor package carefully during the first hours of operation for any possible malfunction. Attention! Important functional components in the compressor package (such as minimum pressure check valve, safety relief valve, inlet valve and combination valve) are adjusted and fitted to factory standards and specifications. Alterations to these components are not allowed without prior written authorization with the manufacturer. Do not disassemble the minimum pressure check valve, safety relief valve and inlet valve. They are heavily spring loaded. Disassembly by unqualifed personnel may result in personal injury or equipment damage.

7.2

Points to be Observed before Starting the Compressor Unit


ANY NON -- OBSERVANCE OF THIS OR OTHER REFERENCES (WARNING; ATTENTION; DANGER ) CAN LEAD TO ACCIDENTS CAUSING INJURY TO PERSONS OR DAMAGE TO EQUIPMENT. If a power failure occurs, the compressor package starts again automatically (normal setting) provided the line pressure is lower than the pressure threshold parameter entered in SIGMA CONTROL. Do not operate the compressor with open maintenance doors or with cover panels removed as personnel could be injured by rotating parts and electrical equipment.  Remove all packaging materials, tools and transport securing devices on and in the compressor package. The operator is expected to practice safe working techniques and to follow all recommended operating and safety regulations when operating this compressor package. The operator of this compressor unit is responsible for its safe operating condition. Do not operate this compressor unit in locations where high dust conditions, poisonous, or inflammable gases could exist. Do not connect the compressor package to a supply voltage other than that stated on the nameplate. Do not install the compressor package in a location subject to freezing temperatures. The air temperature requirements at the air intake must be complied with (see chapter 1.6). If exhaust air ducts are to be installed the duct cross section must be equal or larger than the cooling air outlet of the compressor package and may not exceed the permitted pressure loss prescribed by the compressor manufacturer.

7 --- 22

Initial Start
 During installation of the compressor unit, ensure that a distance of at least 40 is kept between the cooling air intake of the unit and any wall. Check the oil level in the oil separator tank (see chapter 9.12). Check that the airend rotates in the correct direction (see chapter 7.4). Check the tension of the drive belts (see chapter 9.4). The ball valve (6.6, see chapter 5.3) must be closed. The ball valve (20, see chapter 5.3) must be open. Lock the main disconnect in the off position in accordance with applicable lock out/tag out procedures (example: OSHA CFR 29 1910.147) to ensure the compressor does not restart. Check all screws on the electrical connections for tightness and tighten if necessary (carry out this check again after 50 hours of operation). This compressor is fitted with a run ---in oil filter cartridge. Replace the filter cartridge after the run ---in period of 200 hours (see chapter 9.11).

  

7 --- 23

Initial Start
7.3 Checklist
      yes  no  yes  no  yes  no  yes  no Is the floor at the place of installation solid and level?

Is the space large enough for the compressor package or its components? Are inlet and exhaust air apertures available in sufficient size and number?

Are all components of the compressor package easily accessible? Is the power supply cable of sufficient cross---section? (have electrical connection carried out by qualified electrician or company familiar with local conditions) Is a shut off valve fitted by the user?

 

 yes  no  yes  no

    

 yes  no  yes  no  yes  no  yes  no  yes  no

Is a flexible connecting hose or axial compensator fitted between the compressor package and the compressed air system?

Have all screws, bolts and electrical connections been checked for tightness? Has the oil level in the oil separator been checked?

Is a main disconnect switch fitted (suited to the motor starting characteristics)? Has the setting of the drive motor overload current trip been checked?

 yes  no  yes  no

Have you ensured that there are no other air components located in the exhaust air flow of the compressor package?

Have service personnel been instructed on safety regulations?

7 --- 24

Initial Start
7.4 Direction of Rotation Check
Attention! The compressor is wired for connection to a clockwise phase sequence power supply.

A check of the direction of rotation can be made by testing the phase sequence. Arrows showing the direction of rotation are located on the motor and on the airend housing.  On your initial start, bump the unit and verify the direction of rotation.

If the direction of rotation is incorrect, change over the supply conductors L1 and L2. Attention! If the airend rotates in the wrong direction, the compressor is automatically shut down by the safety air pressure switch (4.2, see chapter 5.3).

7.5

Motor Overload Relay Adjustment


Lock the main disconnect in the off position in accordance with applicable lock out/tag out procedures (example: OSHA CFR 29 1910.147) to ensure the compressor does not restart. See chapter 2.3 for the main disconnect switch. The relay is set to the standard adjustment at the factory. Compressor motor: Wye -- delta start In the Wye---delta configuration the phase current is fed through the motor overload relay. This phase current is 0.58 times the nominal motor current. For the nominal motor current see motor nameplate. Adjustment: To prevent the overload relay from tripping (because of voltage fluctuations, temperature influences or component tolerances), the value can be set up to 15% higher than the calculated phase current.

1 2

1 Motor overload adjustment 2 Reset button

7 --- 25

Initial Start
7.6 Setting the Air System Pressure
The air system pressure is preset at the factory. It can be changed in SIGMA CONTROL to match customers operational requirements if the password is known. For further details, consult the SIGMA CONTROL service manual. Attention! Switching from full load to idle running may take place no more frequently than 2 times per minute.

Switching frequency can be improved by increasing the difference between cut ---in and cut ---out pressure. In addition, a larger air receiver can be installed to increase buffer capacity.

7.7

Functional Check of the Door Interlock Switch


Do not operate the compressor unit with a malfunctioning door interlock switch. Do not attempt to modify or by-- pass the door interlock switch.

1 1 Door interlock switch Visual door interlock switch check  Check that the interlock switch operates smoothly by opening and closing the left --hand maintenance door. If the insertion key (3) at the door interlock is incorrectly aligned, inadvertent shutdown of the compressor package can occur. The insertion key (3) aligns with the door interlock switch (1) without binding against the sides of the interlock switch when the maintenance door is closed. If necessary, re---align the insertion key (3).  Loosen the bolts (4).

Attention!

7 --- 26

Initial Start
  Align the insertion dey (3) so that it glides smoothly into the interlock switch (1). If necessary, use washers to help align the insertion key (3) with the interlock switch (1). Tighten the bolts (4) again.

6 2

2 3 4 4 5 1

1 Door interlock switch 2 Clamping nut 3 Insertion key Functional check of the interlock switch Attention!    

4 5 6

Bolt Frame Maintenance door

A functional check of the door interlock switch must be made after initial start.

Start the compressor package (see chapter 8.3). Open the left ---hand maintenance door --- the compressor package will shut down immediately if the door interlock switch functions correctly. Close the left ---hand maintenance door. Reset the alarm message by pressing the acknowledge (reset) key (11, see chapter 8.2.2) on SIGMA CONTROL.

The compressor package is now ready to start again.

7 --- 27

Initial Start
7.8 Measures to be taken before Initial Start
Follow the procedure detailed bellow before initial start, after an oil change or if the compressor has not been operated for a period of three months or longer before starting the compressor: 7.8.1 Pour a small quantity of oil into the air inlet port Lock the main disconnect in the off position in accordance with applicable lock out/tag out procedures (example: OSHA CFR 29 1910.147) to ensure the compressor does not restart. Do not add oil unless the compressor package is completely vented. See chapter 9.10 to vent the compressor.    To pour in the oil, unscrew the filler plug (1) on the inlet valve (2) and then pour the prescribed quantity of oil (see chapter 1.7) into the airend. Manually rotate the airend in a counter clockwise direction with the drive belts. Screw the filler plug (1) back in. This oil must be of the same type as the oil used to operate the compressor (see label near the oil filler plug on the oil separator tank). If no additional oil is available, remove required amount of oil from the oil separator tank. See chapter 9.14 for this procedure. If the compressor unit was at standstill for more than 12 months, additional precautionary steps have to be taken before putting the unit back into operation. In this case consult the manufacturer.  Open the isolation shut ---off valve between the compressor and the compressed air system. 1

Attention!

1 Filler plug 2 Inlet valve 7.8.2 Running the compressor in idle At initial start run the compressor package in idle for 20 seconds by pressing the load/idle key (5, see chapter 8.2.2). This measure ensures that the compressor package has sufficient time to flood the oil circulation. If a power failure occurs, the compressor package will start again automatically (normal setting) when the power is restored provided the system pressure is lower than the cut-- in pressure entered in the SIGMA CONTROL.

7 --- 28

Operation
8
8.1

Operation
Control Panel

1 2

1 SIGMA CONTROL 2 EMERGENCY STOP pushbutton

8.2

SIGMA controller
The SIGMA controller (1) is fitted in the control cabinet in the compressor package and serves as the control panel. It has 11 keys and 9 LEDs. Operation of the compressor package is determined by the settings programmed into the controller. Further details on individual function keys, LEDs and plain text display relating to possible alarms and service messages, display of events, etc. are given in the service manual supplied for the SIGMA CONTROL controller.

8.2.1

Emergency Stop Pushbutton The Emergency Stop pushbutton shuts down the compressor package immediately. If the Emergency Stop pushbutton is pressed because of an existing hazard, then this must be eliminated before the compressor package is reset. To accomplish this the following procedure must be carried out:   Unlatch the Emergency Stop pushbutton by turning in the direction of the arrows. Acknowledge the alarm message on the controller by pressing the acknowledge (reset) key. (function keys see chapter 8.2.2.)

8 --- 29

Operation
8.2.2 Function keys

7 11 10 8 9 6 1 5 2

4 1 2 3 4 5 ON key (I) OFF key (0) Timer ON/OFF key Remote ON key Load/idle key 6 7 8 9 10 11

3 Menu scroll --- DOWN key Menu scroll --- UP key Escape key Return key Info --- event key Acknowledge (reset) key

8.2.3

Light emitting diodes and plain text display

13 14 15 16 17 18 19 12

20 12 13 14 15 16 Four ---line display Alarm LED Communication alarm LED Warning --- maintenance LED Power ON LED (to controller)

21 17 18 19 20 21 Load LED Idle LED Compressor ON LED Remote ON LED Timer ON LED

8 --- 30

Operation
8.3 Starting and Stopping the Compressor Unit
Attention! Do not start and stop the compressor package with the main disconnect switch. The compressor must always be switched ON and OFF with keys (1) and (2).

To turn the compressor ON (local):  Switch on the main disconnect switch.

The controller carries out a self---test. The self---test sequence is visible in the display (12). Afterwards, the green LED (16) illuminates permanently.  Press the ON key (1)--- LED (19) illuminates.

The compressor status is indicated by LEDs (17) and (18): Attention! If LED (19) is illuminated and both LEDs (17) and (18) are extinguished the compressor package is at standstill but on duty. The compressor package can start at any moment. To turn the compressor OFF (local):   Press the OFF key (2) --- LED (19) extinguishes. Lock the main disconnect in the off position in accordance with applicable lock out/ tag out procedures (example: OSHA CFR 29 1910.147) to ensure the compressor does not restart.

See chapter 2.3 for the main disconnect switch.

8.4

Acknowledgement of Alarms
If an alarm occurs the compressor package is shut down immediately and the red LED (13) on SIGMA CONTROL flashes. The bottom line in the display (12) shows the actual fault causing the alarm. A list of alarms that may occur during operation is included in the SIGMA CONTROL service manual.   Remove the fault. Acknowledge alarm with the reset key (11) --- LED (13) extinguishes.

The compressor package is now ready to start again. Attention! If the compressor was shut down with the EMERGENCY STOP pushbutton, then reset by rotating the latched pushbutton in the direction of the arrow before acknowledging the alarm.

8 --- 31

Operation
8.5 Acknowledgement of Service Messages
When maintenance is due the yellow LED (15) on SIGMA CONTROL flashes. Maintenance due is shown in the display (12). A list of service messages that may occur during operation is included in the SIGMA CONTROL service manual.   Carry out the maintenance work. Acknowledge service message with the reset key (11) --- LED (15) extinguishes. When the respective maintenance has been carried out, the remaining interval period (programmed interval until the next maintenance is due) must be reset.

Attention!

Detailed information on resetting service counters is to be found in the service manual for SIGMA CONTROL.

8 --- 32

Operation
8.6 Trouble shooting: Possible cause ---Remedy
The removal of faults that are not explicitly described in this service manual may only be carried out by KAESER or by an authorised KAESER service agency. 8.6.1 Airend temperature is too high (greater than 167F-- 200F) Possible cause: Cooling air inlet or outlet is too close to wall or other blockage. Air intake filter mats are clogged. Ambient temperature is too high. Remedy: Situate unit for adequate air flow. Clean the mats or replace if necessary. Provide cooler air from other source or move compressor to a cooler location. See chapter 1.6. Provide warmer air from other source or move compressor to warmer location or add a cabinet heater. See chapter 1.6. Provide required amount of ventilation. Consult authorized KAESER distributor for duct requirements. Clean with compressed air, water or steam injector. See chapter 9.13. Inspect heat exchanger elements. Clean or replace as necessary. Check oil level and add necessary amount of recommended oil. Check dirt trap strainer in oil return line for possible contamination. Thermostatic valve is not functioning correctly. Idle pressure is too low for proper oil circulation. Check the valve spring and actuating piston. Replace defective parts. Check idle pressure at the separator tank. If the pressure is low check the inlet valve. Adjust inlet valve to maintain adequate idle pressure. Drain old oil completely and replace with recommended type. Consult authorized KAESER distributor for other oil types not listed. Oil filter is clogged. Airend is defective. Replace filter. Check airend and replace if defective.

Ambient temperature too low.

Cooling air supply is inadequate. If cooling air outlet duct is used it may be too narrow or too long. On air cooled units the fins of the coolers (oil cooler and air aftercooler) are clogged. On water cooled units the heat exchanger elements may be clogged. Oil level is low.

Wrong oil is used.

8 --- 33

Operation
8.6.2 Motor overload relay switches the unit off

Possible cause: Overload relay is defective or setting is wrong. Motor is running two phase: defective motor or blown fuse. Oil separator cartridge is contaminated. Motor starts against pressure because system does not get vented.

Remedy: Check line current and adjust overload relay as necessary. Replace relay if defective. Check input power, check wiring, tighten any loose connections. Replace fuse(s) or motor if necessary. Check pressure differential across cartridge. Replace cartridge and dirt trap strainer if necessary. Check ball valve in vent line and open if it is closed. Check the diaphragm in the vent valve and replace if defective. Check the minimum pressure check valve. Adjust minimum pressure function or replace defective parts as necessary.

Airend is defective.

Ambient temperature is above 104F. Defective motor: bad bearings or short circuit in windings.

Check airend and replace if defective. Provide adequate compressor ventilation. Repair or replace motor.

8.6.3

Compressor is running but produces no pressure

Possible cause: Airend rotates in wrong direction. Inlet valve does not open or opens only partially. Vent valve does not close at full load.

Remedy: Reverse motor polarity. Check the inlet valve, control valve and lines. Replace defective parts as needed Check the combined control/vent valve and control lines. Replace defective parts as needed. Check the valve and replace defective parts. Check for open valves, loose connections, defective tools, etc. Reduce system demand or install additional compressor(s). Tighten loose connections, repair or replace defective parts as necessary. Remove socket from coupling.

Minimum pressure check valve is defective. Leaks in plant system. Plant system air, demand exceeds capacity of compressor Air leak in unit. Socket is still in the hose coupling at the oil separator tank or aftercooler.

8 --- 34

Operation
Safety relief valve has blown off. Airend is defective. See chapter 8.6.6. With unit running, slowly and carefully place hand over air inlet filter casing. There should be considerable suction. If not, airend is producing no pressure.

8.6.4

Oil leaks out of air filter Possible cause: Oil level in separator tank is too high. Inlet valve faulty. Remedy: Drain oil to correct level. Find the fault and replace the defective part.

8.6.5

Full -- load/Idle sequence occurs too frequently (short cycles) Possible cause: Receiver tank size is too small or there is no tank. Diameter of hose connecting the unit to the receiver tank is too small. Remedy: Consult authorized KAESER distributor for recommended tank size. Connecting hose diameter should not be smaller than the air discharge pipe diameter. Install larger hose if necessary. Check the valve and replace defective parts. Look for plugged filters, partially closed valves, frozen pipes or malfunctioning pressure regulators.

Minimum pressure check valve leaks. Flow is restricted at discharge.

8.6.6

Safety relief valve blows off Possible cause: System does not discharge at idle. Remedy: Make sure ball valve in vent line is open. Check the control lines, inlet valve and combined control/vent valve. Replace defective parts as needed. Check the cartridge pressure differential and replace cartridge if necessary. Check the valve for blockage and replace defective parts as necessary. Check blow ---off pressure and compare to name plate of the compressor. Replace if necessary.

Oil separator cartridge is contaminated. Minimum pressure check valve does not open. Safety relief valve not properly sized for the pressure of the compressor unit. 8.6.7 Oil inside the unit Possible cause: Socket is still in the hose coupling at the separator tank. Safety valve has blown off. Oil is coming out of air filter. Hose coupling on separator tank is loose. Oil cooler leaks.

Remedy: Remove the socket from the coupling. See chapter 8.6.6. See chapter 8.6.4. Tighten coupling or replace as needed. Replace oil cooler.

8 --- 35

Operation
8.6.8 Excessive oil consumption Possible cause: Wrong oil is being used in the unit. Remedy: Replace with correct oil type. Consult authorized KAESER distributor for other oil types not listed. Oil separator cartridge has ruptured. Check pressure differential and replace oil separator cartridge if necessary. Tighten mounting bolts. Drain oil to correct level. Inspect dirt trap strainer in scavenger line. Clean or replace clogged parts as necessary.

Oil separator cartridge mountings are loose. Oil level in separator tank is too high. Scavenger line is clogged.

8 --- 36

Maintenance
9
9.1

Maintenance
Observe the following rules during all maintenance and servicing work:
Work on power driven equipment may only be carried out by trained or specialized personnel. Follow all applicable OSHA and local safety regulations. If a power failure occurs, the compressor package starts again automatically (normal setting) provided the line pressure is lower than the pressure threshold parameter entered in SIGMA CONTROL. Lock the main disconnect switch in the off position in accordance with applicable lock out/tag out procedures to ensure the compressor does not restart (see chapter 2.3 for main disconnect switch). Ensure that no maintenance personnel is working on the compressor unit, that all panels are latched back on again and all maintenance doors are closed before restarting the compressor unit. To start the compressor unit see chapter 8.3). Attention! The venting nozzle required to vent the oil separator tank (for maintenance work such as topping up the oil, oil change and filter change) is fitted to the hose coupling (3, see chapter 9.10). Carry out a visual and functional check of the door interlock switch after any maintenance and servicing work. See chapter 7.7 for details. The following points must be observed when handling lubricating and cooling materials: Avoid contact with skin and eyes. Do not inhale vapors and oil mist. Do not eat or drink when handling such materials. Fire, open flame and smoking are strictly forbidden. Ensure that all lubricants, consumable materials and replacement parts accumulating during operation and servicing of the compressor package are disposed of according to environmental regulations.

9 --- 37

Maintenance
9.2 Regular Maintenance
Interval* 2 and 24 h after initial start 50 h after initial start 200 h after initial start Weekly Work to be done Check the v---belt tension Check all electrical connections for tightness and tighten if necessary Replace the oil filter Check the oil level Check the filter mats for contamination 500 h Check the v---belt tension Clean or replace the air filter 1000 h Check the oil cooler and air aftercooler for contamination Clean or replace the filter mats up to 3000 h or at least annually Proper interval varies. See chapter 1.8 Replace the oil filter Change the oil 9.11 9.12 9.6 9.4 9.7 9.13 9.6 9.11 9.14 9.15 See chapter 9.4

up to 9000 h or at least Change the oil separator cartridge every 3 years Annually 12000 h Annually Check all electrical connections for tightness and tighten if necessary Have the valves inspected by an authorized KAESER Service agent Have the safety relief valve checked by authorized KAESER Service agent

9.9 9.8

6000/12000 hours or at Have the compressor motor bearings relubricaleast within three years ted by authorized KAESER distributors* *

The maintenance period can vary depending on the cycle rate and environmental conditions.

We urgently recommend that a record is kept of the maintenance work done (see chapter 9.16).

9 --- 38

Maintenance
9.3 Opening and Closing the Compressor Package
To open:     Open the maintenance door (1). Move the lever (A) in the direction of the arrow and lift up the maintenance door (2). Loosen the screws (B) and remove the panel (3).

To close: Close the panel (3) the maintenance door (2) and the maintenance door (1) in the reverse order. Close all maintenance doors and panels correctly before starting the compressor package.

A
3 1

B B

1 Maintenance door 2 Maintenance door 3 Cover panel

9 --- 39

Maintenance
9.4 Checking the Drive Belt Tension
 Switch off the compressor unit (see chapter 8.3). Lock the main disconnect switch in the off position in accordance with applicable lock out/tag out procedures to ensure the compressor does not restart. Check the tension of the belt drive after the first 2 and 24 hours of operation and thereafter every 500 hours of operation.

2 1

1 Hexagonal nut 2 Hexagonal nut 3 Indicator pin The belt drive tension is automatically adjusted within a limited range by the pressure spring of the belt tensioning device. Re---tension the belt drive if the belts have stretched to the point where the indicator pin (3) is situated at the top end of its indicator slot.    Loosen the hexagonal nut (2). Tension the belt drive with the hexagonal nut (1) until the indicator pin (3) is situated at the bottom end of its indicating slot. Tighten the hexagonal nut (2).

9.5

Drive Belt Change


 Switch off the compressor unit (see chapter 8.3). Lock the main disconnect switch in the off position in accordance with applicable lockout/tagout procedures to ensure the compressor does not restart.    Loosen the hexagonal nut (2, see chapter 9.4). Screw the hexagonal nut (1, see chapter 9.4) until the V---belts are loose. Remove the V---belts. It is essential that replacement belts are all precisely the same length (each set) and absolutely oil -- proof. For this reason we recommend that only original KAESER drive belts are used.

Attention!

9 --- 40

Maintenance
  Place the new V---belts over the motor and compressor pulleys without straining them. Set the belt drive tension (see chapter 9.4). Check the belt drive tension after 2 hours of operation and then again after 24 hours of operation, as experience shows that the belts stretch mostly during this period.

Attention!

9.6

Cleaning or Replacing the Filter Mat


Clean the filter mat every week depending on the dust content of the intake air and replace if necessary as detailed in the maintenance schedule (see chapter 9.2).  Switch off the compressor package (see chapter 8.3). Lock the main disconnect switch in the off position in accordance with applicable lockout/tagout procedures to ensure the compressor does not restart. 3 2 3

2 3

3 1 Filter 2 Holding frame 3 Closure  Press closures (3) inwards and remove the holding frame.

Cleaning:

Rinse the mat in warm water ( approximately 105F), if necessary, use a mild detergent soap to rinse out oily dust. The mat can also be tapped, vacuum cleaned or blown out with compressed air (not in excess of 30 psig). Attention!  If the mat is heavily soiled or has been cleaned often (maximum five times), replace it.

Locate the holding frame and press into position.

The holding frame is secure when the closures engage.

9 --- 41

Maintenance
9.7 Cleaning or Replacing the Air Filter
Clean the air filter after every 500 service hours.  Stop the compressor package (see chapter 8.3). Lock the main disconnect switch in the off position in accordance with applicable lock out/tag out procedures to ensure the compressor package does not restart. 4 2

1 1 2 3 4 Air filter Air filter cap Wing nut for opening air filter housing Air filter cartridge

To open the air filter housing:  Unscrew the wing nut (3) and remove the air filter cap (2) and the filter cartridge (4).  Clean the air filter cap and sealing surfaces. Cleaning the air filter cartridge (4) by tapping:  Tap the air filter cartridge several times on the front with the ball of the hand. Attention!  Do not use excessive force otherwise the air filter cartridge may be damaged.

Clean all sealing surfaces.

Cleaning the air filter cartridge with compressed air:  Use dry, compressed air blowing at a pressure of not more than 30 psig at a slant from the inside to the outside of the air filter cartridge surfaces. Attention! Do not clean the air filter cartridge with fluids. If the air filter cartridge is heavily contaminated or was already cleaned several times (max. five times), replace. Compressed air shall not be used for cleaning purposes except where reduced to less than 30 psig and then only with effective chip guarding and personal protective equipment. (OSHA CFR 29 1910.242)   To close the filter housing: Insert the filter cartridge (4) and replace the air filter cap (2). Screw on the wing nut (3) tightly.

9.8

Servicing the Electric Motor


Compressor motor: The electrical motor bearings are permanently greased. Attention! Have the motor bearings replaced by authorized KAESER distributors in accordance with the maintenance schedule (see chapter 1.9).

9 --- 42

Maintenance
9.9 Testing the Safety Relief Valve on the Oil Separator Tank
To test the set point of the safety relief valve, the compressor must be run so that its discharge pressure exceeds the maximum pressure set on the SIGMA CONTROL. See chapter 1.5 for the safety relief valve activating pressure. Attention! Have the safety relief valve tested by an authorized KAESER distributor in accordance with the maintenance schedule (see chapter 9.2). For more details see SIGMA CONTROL manual.

9.10

Venting the compressor unit


 Switch off the compressor unit (see chapter 8.3). Lock the main disconnect in the off position in accordance with applicable lock out/tag out procedures to ensure the compressor does not restart. Lock the isolation shut-- off valve in the closed position and vent all compressed air trapped between the compressor and the isolation shut-- off valve in accordance with applicable lock out/ tag out procedures. The oil circulation system of the compressor package vents automatically. Venting the oil separator tank: 11 6

A B

3 2 4 5

1 9 10 8 7

1 Ball valve A shut B open 2 Pressure gauge 3 Hose coupling

4 Filler plug (oil top --- up) 5 Oil separator tank 6 Nozzle 7 Minimum oil level

8 9 10 11

Maximum oil level Ball valve --- oil drain Oil drain hose External pressurization

9 --- 43

Maintenance
 The pressure gauge on the oil separator tank must indicate zero psig. Oil mist can escape when the oil separator tank is vented.  

Insert the nozzle (6) in the hose coupling (3) on the oil separator tank. The residual pressure in the oil separator tank escapes. Remove the nozzle (6) from the hose coupling (3).

Venting the air aftercooler: When the compressor package is vented, pressure is still present in the air aftercooler and the pipework up to the minimum pressure check valve. For this reason the compressor package must be isolated from the compressed air system by closing the shut-- off valve between the compressor package and the compressed air system. If isolation shut-- off valve is not available, vent the compressed air system completely.  Carefully remove the screw fitting (4, see chapter 9.13). The air aftercooler vents. Tighten the screw fitting again. Close all maintenance doors and panels correctly before starting the compressor package.

9.11

Oil Filter Change


Hot oil; beware of scalding.

Attention!

Replace the run-- in oil filter cartridge with a standard oil filter cartridge (supplied with the compressor) after approximately 200 operating hours.

Change the oil fillter cartridge according to the regular maintenance schedule (see chapter 9.2) or when the corresponding service message is displayed on SIGMA CONTROL (see chapter 8.1). It is recommended that the oil filter cartridge is replaced always when the oil is changed. 9.11.1 Removal and replacement of the oil filter cartridge  Stop the compressor package under full load (see chapter 8.3). Lock the main disconnect in the off position in accordance with applicable lock out/tag out procedures (example: OSHA CFR 29 1910.147) to ensure the compressor does not restart. Before opening or removing pressurized components (pipes, hoses, tanks, etc.) it is imperative that the compressor package is completely depressurized.  Venting the compressor package (see chapter 9.10).

9 --- 44

Maintenance

1 2

1 Oil filter cartridge 2 Turn in this direction to unscrew the cartridge  Twist the used or contaminated oil filter cartridge counter clockwise to remove and catch escaping oil in a suitable container. Dispose of the old oil filter and any used, accumulated oil according to environmental care regulations!  Clean the face of the combination block with a lint free cloth. Lightly oil the gasket of the new filter cartridge before screwing into position. Screw in the new filter cartridge clockwise by hand until the gasket fits tightly. Do not use a tool as this may cause damage to the oil filter cartridge and the gasket.

Attention!  

Check the oil level (see chapter 9.12). Open the isolation shut ---off valve between the compressor and the compressed air system. Perform a test run When the operating temperature is reached (see chapter 1.1), shut down the compressor package (see chapter 8.3) and lock the main disconnect in the off position in accordance with applicable lock out/ tag out procedures (example: OSHA CFR 29 1910.147) to ensure the compressor does not restart. Afterwards, carry out a visual check for leaks.

9.12

Oil Top ---Off


Check the oil level weekly through the oil sight glass when the compressor is shut down. If necessary, top off the oil to the maximum level. Do not exceed the maximum level (center of the top oil sight glass).  Stop the compressor package under full load (see chapter 8.3). Lock the main disconnect in the off position in accordance with applicable lock out/tag out procedures (example: OSHA CFR 29 1910.147) to ensure the compressor does not restart. Before opening or removing pressurized components (pipes, hoses, tanks, etc.) it is imperative that the compressor package is completely depressurized.

9 --- 45

Maintenance
 Venting the compressor package (see chapter 9.10). 11 6

A B

3 2 4 5

1 9 10 8 7

1 Ball valve A shut B open 2 Pressure gauge 3 Hose coupling    

4 Filler plug (oil top --- up) 5 Oil separator tank 6 Nozzle 7 Minimum oil level

8 9 10 11

Maximum oil level Ball valve --- oil drain Oil drain hose External pressurization

Unscrew the oil filler plug (4) on the oil separator tank. Top off the oil to the maximum mark. Check the gasket ring of the filler plug (4) for damage and then screw in the filler plug. Open the isolation shut ---off valve between the compressor and the compressed air system. After an oil change or oil cooler cleaning (with removal of the oil cooler) run the compressor package up to operating temperature to ensure that the combination valve closes and that the oil cooler is flooded with oil. Afterwards, repeat the procedures Venting the Compressor Package (chapter 9.10) and Topping off the Oil (chapter 9.12).

Attention!

Attention!

Always use the same brand and type of oil when topping off the oil. (see label on the oil separator tank). During an oil change, drain the old oil completely and always replace the oil filter. Never mix different oil types or brands. Oil recommendations see chapter 1.8

9 --- 46

Maintenance
9.13 Cleaning the Oil Cooler and Aftercooler
The oil cooler and air aftercooler must be checked for clogging regularly. Heavy contamination could lead to excessive temperatures in the oil circulation system. See regular maintenance schedule for cooler maintenance interval (chapter 9.2).  Switch off the compressor package under full load (see chapter 8.3). Lock the main disconnect in the off position in accordance with applicable lock out/tag out procedures to ensure the compressor does not restart. Before opening or removing pressurized components (pipes, hoses, tanks, etc.) it is imperative that the compressor package is completely depressurized.  9.13.1 Venting the compressor package (see chapter 9.10).

Removing and cleaning the oil cooler/air aftercooler 1 1 2 4 3

1 2 3 4    

Allen screw Hose screw fitting Pipe screw fitting Pipe screw fitting Unscrew the hose connector (2) and the pipe connector (3) from the combination valve. Unscrew the Allen screws (1) on the aftercooler. Remove and check the O---ring on the aftercooler. Close up the pipes and openings on the combination valve, and aftercooler.

9 --- 47

Maintenance

6 5 Hexagonal nut 6 Allen screw  Unscrew the hex bolt (5).

The hex socket head bolts (6) are located behind two protective caps. Attention!  Before unscrewing the two hex socket head bolts (6) prop up the combination oil/air aftercooler.

Remove the protective caps and unscrew the two hex socket head bolts (6). Take out the aftercooler. Do not direct compressed air, water or steam jets toward any person. These represent contained energy and as such, are dangerous to life. The soiled cooler laminations may be cleaned with water or steam jet only in designated cleaning areas with oil separators suited for such purpose!

Clean the cooler laminations with compressed air, water or steam jet. Seat the O -- rings correctly in the compressed air inlet of the oil/air aftercooler during reassembly.

Attention!   

Reassemble in the reverse order. See chapter 9.12 for topping off the oil. Open the isolation shut ---off valve between the compressor and the compressed air system. Perform a test run When the operating temperature is reached (see chapter 1.1), shut down the compressor package (see chapter 8.3) and lock the main disconnect in the off position in accordance with applicable lock out/ tag out procedures (example: OSHA CFR 29 1910.147) to ensure the compressor does not restart. Afterwards, carry out a visual check for leaks.

9.14

Oil Change (Oil Separator Tank and Oil Cooler)


For type of oil and frequency of oil change see chapter 1.8

9 --- 48

Maintenance
Oil change must be carried out with warm to the touch condition of the compressor package (Oil temperature approx. 104F). Danger of scalding with hot oil. When inserting the maintenance hose into the compressors hose couplings, always have the ball valve closed and the hose end secured before slowly opening the ball valve. Beware of air/oil mist that could blow out of the hose. Unrestricted air/oil flow through the hose end will result in a whipping action which could cause severe injury or death. If the compressor package operates in ambient temperatures close to the maximum ambient temperature (see chapter 1.6), change the oil more often (e.g. 1/2 or 1/4 of recommended interval). Attention! Attention!  Drain the oil out of the oil separator tank, cooler and the oil pipes completely. See chapter 9.14.4 for putting back into operation. If a heat recovery system is fitted drain all the oil in the heat exchanger during the oil change.

Stop the compressor package under full load (see chapter 8.3). Lock the main disconnect in the off position in accordance with applicable lock out/tag out procedures (example: OSHA CFR 29 1910.147) to ensure the compressor does not restart. 11 6

A B

3 2 4 5

1 9 10 8 7

1 Ball valve A shut B open 2 Pressure gauge 3 Hose coupling

4 Filler plug (oil top --- up) 5 Oil separator tank 6 Nozzle 7 Minimum oil level

8 9 10 11

Maximum oil level Ball valve --- oil drain Oil drain hose External pressurization

9 --- 49

Maintenance
Before opening or removing pressurized components (pipes, hoses, tanks, etc.) it is imperative that the compressor package is completely depressurized.  9.14.1 Venting the compressor package (see chapter 9.10).

Oil change using external pressure source   Close the ball valve (1). Insert the nozzle (6) in the hose coupling (3) on the oil separator tank (5). Connect the nozzle to external pressure source. Pressurize the oil separator tank (5) until the pressure gauge (2) on the oil separator tank (5) shows approximately 43.5 psig. Remove the nozzle (6) from the hose coupling (3) on the oil separator tank (5).

  

Drain the oil from the oil separator tank: Prepare a clean container to catch escaping oil. The container must be large enough to hold the total oil content of the compressor unit (see chapter 1.7).

Attention!  

Hang the oil drain hose (10) into the container and secure. Slowly open the ball valve (9). The remaining pressure in the oil circulation forces out the oil. When air escapes, close the ball valve (9) immediately. Before opening or removing pressurized components (pipes, hoses, tanks, etc.) it is imperative that the compressor package is completely depressurized.

Venting the compressor package (see chapter 9.10).

1 1 Oil drain plug (oil cooler) Drain the oil from the oil cooler:   Prepare an oil container to catch the escaping oil. Slowly unscrew the oil drain plug (1). The oil drains under the force of gravity. Screw the oil drain plug (1) back in tightly. Dispose of the old oil according to environmental regulations.

9 --- 50

Maintenance
9.14.2 Oil top -- off  Unscrew the oil filler plug (4) on the oil separator tank. Always use the same brand and type of oil when topping off the oil. (see label on the oil separator tank). During an oil change, drain the old oil completely and always replace the oil filter. Never mix different oil types or brands. Oil recommendations see chapter 1.8   9.14.3 Top off the oil to the maximum mark.

Attention!

See chapter 1.7 for the quantity of oil. Check the gasket ring of the filler plug (4) for damage and then screw in the filler plug.

Draining the oil using own compressed air  Shut down the compressor unit under full load (see chapter 8.3). Lock the main disconnect in the off position in accordance with applicable lock out/tag out procedures to ensure the compressor does not restart. Lock the isolation shut-- off valve in the closed position and vent all compressed air trapped between the compressor and the isolation shut-- off valve in accordance with applicable lock out/ tag out procedures. The compressor unit oil circulation system vents automatically.   The pressure gauge on the oil separator tank must indicate zero psig. Close the vent line ball valve (1). Close all maintenance doors and panels correctly before starting the compressor package.   Start the compressor package (see chapter 8.3) and allow to run for approximately 30 seconds. Stop the compressor package under full load (see chapter 8.3). Lock the main disconnect in the off position in accordance with applicable lock out/tag out procedures (example: OSHA CFR 29 1910.147) to ensure the compressor does not restart.     Check the actual pressure on the pressure gauge (2). Open the shut ---off valve (1), let the pressure on the pressure gauge (2) sink to approximately 40 psig and then close the shut ---off valve (1) again. Drain the oil from the oil separator tank and the oil cooler. Proceed as detailed in chapter 9.14.1). Open the shut ---off valve (1). Top off the oil. Proceed as detailed in chapter 9.14.2).

9 --- 51

Maintenance
9.14.4 Procedure for putting back into operation  Refer to chapter 7.8.1 and follow the instructions in section Pouring a small quantity of oil into the air inlet port . Refer to chapter 7.8.2 and followthe instructions in section Running the compressor package in idle. Refer to chapter 9.10 and follow the instructions in section Venting the compressor package. Top off with oil again (see chapter 9.14.2). Open the shut ---off valve between the compressor package and the air system. Start the compressor package (see chapter 8.3) and run until working temperature is reached (see chapter 1.1). Top off the oil, see chapter 9.12. Perform a test run When the operating temperature is reached (see chapter 1.1), shut down the compressor package (see chapter 8.3) and lock the main disconnect in the off position in accordance with applicable lock out/ tag out procedures (example: OSHA CFR 29 1910.147) to ensure the compressor does not restart. Afterwards, carry out a visual check for leaks.

    

9.15

Changing the Oil Separator Cartridge


The service life of the oil separator cartridge is strongly influenced by the degree of contamination of inlet air and on strict adherence to the recommended maintenance intervals of the air and oil filters. We recommend that the oil separator cartridge is changed with the oil or when the relevant service message / alarm message is displayed on SIGMA CONTROL (see chapter 8.1).  Stop the compressor package under full load (see chapter 8.3). Lock the main disconnect in the off position in accordance with applicable lock out/tag out procedures (example: OSHA CFR 29 1910.147) to ensure the compressor does not restart. Before opening or removing pressurized components (pipes, hoses, tanks, etc.) it is imperative that the compressor package is completely depressurized.  Venting the compressor package (see chapter 9.10).

9 --- 52

Maintenance

6 7 4 2 3 5 7 6 9 8

10 11 12 2 Hose coupling 3 Pressure gauge 4 Hexagonal nut 5 6 7 8 Cover Gasket Staple Oil separator cartridge 9 10 11 12 O ---Ring Gasket Dirt trap screen filter Screw fitting with jet

Do not remove the staples (7) in the gaskets (6). The metal parts of the oil separator cartridge are electrically conductive and thus have to be grounded: The gaskets (6) are supplied with heavy staples to provide an electrical path from the oil separator tank to the frame of the compressor unit.  Unscrew the hexagonal bolts (4) and remove cover plate (5). Dispose of the used oil separator cartridge according to environmental regulations!   Take out the old oil separator cartridge (8) together with the gaskets (6) and O--ring (9). Dispose of the old parts according to environmental regulations. Clean the sealing surfaces of the oil separator tank. When cleaning the sealing surfaces, make sure that no dirt particles fall into the oil separator tank. The oil separator cartridge is a disposable item and cannot be cleaned.     Insert the new O---ring (9) in the groove in the oil separator tank. Insert the new oil separator cartridge (8) with new gaskets (6), fit and tighten down the cover plate (5) with the hexagonal bolts (4). Replace the screen filter (11) and the gasket (10) when the oil separator cartridge (8) is replaced. Open the isolation shut ---off valve between the compressor and the compressed air system.

Attention!

9 --- 53

Maintenance
Perform a test run When the operating temperature is reached (see chapter 1.1), shut down the compressor package (see chapter 8.3) and lock the main disconnect in the off position in accordance with applicable lock out/ tag out procedures (example: OSHA CFR 29 1910.147) to ensure the compressor does not restart. Afterwards, carry out a visual check for leaks.

9 --- 54

Maintenance
9.16 Maintenance Schedule
Model No. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Serial No. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Date

Description of work

Operating hours

Signature

9 --- 55

Spare Parts and After Sales Service


10 Spare Parts and After Sales Service

10.1

Service parts and maintenance parts


The removal of faults that are not explicitly described in this service manual may only be carried out by KAESER or by an authorised KAESER service agent.

Model

Part No.

Year

Serial No.

psig Hz/RPM Phase Wiring Diagram

cfm

Voltage Package FLA

HP

Drive Motor FLA

FOR SERVICE, REFER TO EQUIPMENT NUMBER

MADE IN GERMANY

Important for spare parts orders:  Enter the data on the compressor name plate in the name plate shown above.

Always quote the data on the name plate when ordering spare parts. Attention! Always order original spare parts from the compressor manufacturer to avoid lower quality spare parts in your compressor unit.

Supplementary information for specialised personnel concerning spare parts is found in chapter 11.2. Description Oil filter cartridge Air filter cartridge Filter mat Qty. 1 1 1 Order No. 1200 1250 1050

10 --- 56

Spare Parts and After Sales Service


Oil separator cartridge Complete set Comprising: Separating cartridge Gasket O Ring Dirt screen filter Gasket V---belt set

1450

1 2 1 1 1 1 1800

10.2

Service and Maintenance Agreement


We recommend that you take out a service and maintenance agreement with an authorized KAESER distributor. This is your best guarantee of reliable air supplies.

10 --- 57

Appendix
11
11.1

Appendix
Wiring Diagram

11 --- 58

Appendix
11.2 Spare Parts List

11 --- 75